Random overextrusion after 3+hours of printing FW 3.5.2

charliedrums

I’m using a Duet 3 Mainboard 6HC v1.01, Tool board 1LC v1.2 in SBC mode with a Raspberry Pi 5 (64gb card) using the tool distribution board. The 1LC has the Z scanning probe attached and the Orthus Filament Monitor. The extruder is a first gen e3d hemera(Hermes branded)

After I updated to firmware 3.5.2, every time I start a print about between 2 to 4 hours into the print it starts over extruding and a couple of layers into the over extrusion the filament monitor gets triggered because of not enough filament flow and the print stops. At this point I disable the filament monitor and try to continue the print but it keeps over extruding. While over extruding the retractions sound off (with a bit of a whine to them)

When the print is paused, I can jog the extruder but when I try to extrude 100mm of filament at 10mm/s the motor kind of stalls intermittently. This does not happen when the printer is rebooted.

At first, I thought it was the filament so I changed the filament. Still over extrudes after a couple of hours.
Then I thought it might be the extruder so I took it apart and cleaned everything. Still happens a couple of hours into the print.
Reading in the forums I read something about pressure advance (can’t remember what it was) so I disabled it. Same thing.
I tried to go back and downgraded to 3.5.1 but after downgrading same thing happens 2+hours into the print.
At this point I upgraded again to 3.5.2, disassembled the hemera and replaced the motor (I have a spare hemera), thinking it could be a busted motor, same thing happened 4h 20m into the print.

I am at a loss to what it could be. Can it be a busted 1LC board? I don’t want to buy another one if I don’t have to.

The weird thing is, if I cancel the print and try different prints it continues with the weird extruder retraction sound and over extrusion right from the get go. I have to power the printer off and on again and the print starts fine until about the 2-to-4-hour mark.

Here is some info:
Diagnostic at the start of the print:

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91716 of which 3224 recycled
Never used RAM 92212, free system stack 117 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,rWait:,1.0%,821) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,2.0%,211) CanReceiv(6,nWait 1,0.0%,771) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,9.7%,53) MAIN(2,running,87.2%,101) IDLE(0,ready,0.1%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 01:13:06 ago, cause: power up
Last software reset at 2024-06-25 22:42, reason: HardFault undefInstr, Gcodes spinning, available RAM 92500, slot 2
Software reset code 0x4063 HFSR 0x40000000 CFSR 0x00010000 ICSR 0x00400803 BFAR 0x00000000 SP 0x20419930 Task IDLE Freestk 38 ok
Stack: 00000000 a5a5a5a5 a5a5a5a5 fffc0001 a5a5a5af 0049abe9 0049b4fa 61000000 4e49414d 00000000 00000000 00000001 00000002 0d16a016 00000000 2d080000 20380209 00000000 003ffad4 00000000 00000000 00000000 00000000 00000000 003ffff0 20419818 00000002
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 35.5, current 52.6, max 52.7
Supply voltage: min 23.8, current 23.9, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/152/152, gc cycles 0
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, mspos 577, reads 35131, writes 29 timeouts 0
Driver 1: ok, SG min 0, mspos 624, reads 35131, writes 29 timeouts 0
Driver 2: ok, SG min 0, mspos 135, reads 35131, writes 29 timeouts 0
Driver 3: ok, SG min 0, mspos 969, reads 35131, writes 29 timeouts 0
Driver 4: ok, SG min 0, mspos 889, reads 35131, writes 29 timeouts 0
Driver 5: ok, SG min 0, mspos 439, reads 35131, writes 29 timeouts 0
Date/time: 2024-06-25 23:55:56
Slowest loop: 93.76ms; fastest: 0.04ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 190546ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 9 ticks, disabled
Moves shaped first try 3990, on retry 2328, too short 2031, wrong shape 48235, maybepossible 587
=== DDARing 0 ===
Scheduled moves 61489, completed 61429, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 4], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X326.306000 Y332.777008 E0.085130" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 98980, received 127427, lost 0, errs 1, boc 0
Longest wait 2ms for reply type 6031, peak Tx sync delay 380, free buffers 50 (min 48), ts 21935/21934/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 41142/41142
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 1520/3088-0, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiros/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X326.306 Y332.777 E.08513
Buffered code: G1 X325.021 Y332.512 E.09104
Buffered code: G1 X324.798 Y332.419 E.01677
Buffered code: G1 X324.384 Y332.123 E.03531
Buffered code: G1 X324.228 Y331.99 E.01422
Buffered code: G1 X323.882 Y331.632 E.03455
Buffered code: G1 X323.712 Y331.551 E.01307
Buffered code: G1 X323.637 Y331.372 E.01347
Buffered code: G1 X323.653 Y331.182 E.01323
Buffered code: G1 X323.487 Y330.548 E.04548
Buffered code: G1 X323.381 Y329.878 E.04707
Buffered code: G1 X323.342 Y329.089 E.05482
Buffered code: G1 X323.387 Y328.112 E.06787
Buffered code: G1 X323.5 Y327.355 E.05311
Buffered code: G1 X323.673 Y326.613 E.05287
Buffered code: G1 X323.904 Y325.887 E.05287
Buffered code: G1 X324.157 Y325.271 E.04621
Buffered code: G1 X324.549 Y324.489 E.0607
Buffered code: G1 X324.97 Y323.823 E.05467
Buffered code: G1 X325.368 Y323.304 E.04538
Buffered code: G1 X325.805 Y322.826 E.04494
Buffered code: G1 X326.355 Y322.35 E.05047
Buffered code: G1 X326.933 Y321.926 E.04974
Buffered code: G1 X327.926 Y321.432 E.07696
Buffered code: G1 X328.861 Y321.166 E.06745
Buffered code: G1 X329.761 Y321.067 E.06283
Buffered code: G1 X330.017 Y321.11 E.01801
Buffered code: G1 X330.524 Y321.078 E.03525
Buffered code: G1 X331.067 Y321.151 E.03802
Buffered code: G1 X331.607 Y321.277 E.03848
Buffered code: G1 X332.515 Y321.621 E.06738
Buffered code: G1 X333.275 Y322.06 E.0609
Buffered codes: 1536 bytes total
Code buffer space: 1520
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 38.73, max time between full transfers: 41.8ms, max pin wait times: 41.5ms/36.7ms
Codes per second: 14.15
Maximum length of RX/TX data transfers: 6892/1304

1LC diagnostics at the start of the print:

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3220, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,84) HEAT(2,nWait 6,0.4%,94) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,delaying,3.7%,52) MAIN(1,running,90.8%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.8%,112), total 100.0%
Owned mutexes:
Last reset 01:13:09 ago, cause: power up
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 1, write errors 0, ifcnt 17, reads 28909, writes 17, timeouts 4, DMA errors 0, CC errors 0, failedOp 0x71, steps req 0 done 3093220
Moves scheduled 57525, completed 57520, in progress 1, hiccups 0, segs 26, step errors 0, maxLate 0 maxPrep 346, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/8, peak Rx sync delay 243, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 17.5, current 23.6, max 24.6
MCU temperature: min 39.5C, current 55.4C, max 57.5C
Last sensors broadcast 0x00000002 found 1 26 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 89842, send timeouts 0, received 114519, lost 0, errs 1, boc 0, free buffers 18, min 17, error reg 20000
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 365, adv 36211/74681
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 1 to 42us, poll 2 to 1757us
Driver 0: ok

At the beginning of the print, I started a log with M929 S2 but the info is beyond my understanding. I’ll attach it here if it is of any use.

Any idea or recommendation of what to try next?

Thanks in advance.

edit: I had to separate the post because of to many words. See below for diagnostics at the moment of print pausing due to over extrusion.

charliedrums

Diagnostics at the moment the print is paused due to over extrusion:

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 12 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91852 of which 3088 recycled
Never used RAM 92164, free system stack 117 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,rWait:,1.0%,821) HEAT(3,nWait 6,0.0%,321) Move(4,nWait 6,2.7%,211) CanReceiv(6,nWait 1,0.0%,771) CanSender(5,nWait 7,0.0%,325) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,9.7%,53) MAIN(2,running,86.5%,101) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 04:51:37 ago, cause: power up
Last software reset at 2024-06-25 22:42, reason: HardFault undefInstr, Gcodes spinning, available RAM 92500, slot 2
Software reset code 0x4063 HFSR 0x40000000 CFSR 0x00010000 ICSR 0x00400803 BFAR 0x00000000 SP 0x20419930 Task IDLE Freestk 38 ok
Stack: 00000000 a5a5a5a5 a5a5a5a5 fffc0001 a5a5a5af 0049abe9 0049b4fa 61000000 4e49414d 00000000 00000000 00000001 00000002 0d16a016 00000000 2d880000 0038221b 20000000 003ffbf0 00000000 00000000 00000000 00000000 00000000 003ffff0 20419818 00000002
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 51.4, current 51.6, max 53.6
Supply voltage: min 23.7, current 24.0, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/216/216, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: standstill, SG min 0, mspos 632, reads 51389, writes 0 timeouts 0
Driver 1: standstill, SG min 0, mspos 824, reads 51389, writes 0 timeouts 0
Driver 2: standstill, SG min 0, mspos 632, reads 51389, writes 0 timeouts 0
Driver 3: standstill, SG min 0, mspos 472, reads 51389, writes 0 timeouts 0
Driver 4: standstill, SG min 0, mspos 392, reads 51389, writes 0 timeouts 0
Driver 5: standstill, SG min 0, mspos 936, reads 51388, writes 0 timeouts 0
Date/time: 2024-06-26 03:34:27
Slowest loop: 51.20ms; fastest: 0.04ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 28, maxWait 1240ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
no step interrupt scheduled
Moves shaped first try 2936, on retry 3506, too short 5601, wrong shape 228938, maybepossible 1103
=== DDARing 0 ===
Scheduled moves 311800, completed 311800, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is idle in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause* is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 361199, received 373710, lost 0, errs 0, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 381, free buffers 50 (min 48), ts 65555/65555/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 31182/31182
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 0/0-0, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiros/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, paused
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
Code buffer space: 4096
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.23, max time between full transfers: 68.1ms, max pin wait times: 62.9ms/13.3ms
Codes per second: 19.64
Maximum length of RX/TX data transfers: 6892/1304

1LC diagnostics at the moment of the print paused due to over extrusion:

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3196, free system stack 71 words
Tasks: Move(3,nWait 7,0.2%,84) HEAT(2,nWait 6,0.4%,90) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.2%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,nWait 6,3.7%,52) MAIN(1,running,90.7%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.8%,112), total 100.0%
Owned mutexes:
Last reset 04:51:40 ago, cause: power up
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, standstill, SG min 0, read errors 4, write errors 1, ifcnt 235, reads 31529, writes 60650, timeouts 5, DMA errors 0, CC errors 60650, failedOp 0x6f, steps req 0 done 9962542
Moves scheduled 300627, completed 300627, in progress 0, hiccups 0, segs 27, step errors 0, maxLate 0 maxPrep 365, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 1/9, peak Rx sync delay 264, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 20.3, current 24.4, max 24.4
MCU temperature: min 39.5C, current 52.6C, max 57.5C
Last sensors broadcast 0x00000002 found 1 144 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 268805, send timeouts 0, received 413549, lost 0, errs 0, boc 0, free buffers 18, min 17, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 395, adv 36111/74679
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 1 to 84us, poll 4 to 1841us
Driver 0: ok

Here is my config.g:

; Configuration file for Duet 3 (firmware version 3.3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.10 on Wed Feb 16 2022 21:57:55 GMT-0500 (Eastern Standard Time)

; General preferences
M575 P1 S1 B57600                                         ; enable support for PanelDue
G90                                                       ; send absolute coordinates...
M83                                                       ; ...but relative extruder moves
M550 P"duet3"                                             ; set printer name
M669 K1                                                   ; select CoreXY mode
M929 P"eventlog.txt" S1                                   ; start logging warnings to file eventlog.txt

; Wait a moment for the CAN expansion boards to start
G4 S2

; Network
;M552 P0.0.0.0 S1                                          ; enable network and acquire dynamic address via DHCP
;M586 P0 S1                                                ; enable HTTP
;M586 P1 S0                                                ; disable FTP
;M586 P2 S0                                                ; disable Telnet

; Drives
M569 P0.0 S1 ;D3 H30 V30                                          ; physical drive 0.0 goes forwards (X-Y)
M569 P0.1 S1 ;D3 H30 V30                                          ; physical drive 0.1 goes forwards (X-Y)
M569 P0.2 S0                                              ; physical drive 0.2 goes forwards
M569 P0.3 S1                                              ; physical drive 0.3 goes forwards
M569 P0.4 S1                                              ; physical drive 0.4 goes forwards
M569 P0.5 S0                                              ; physical drive 0.5 goes forwards
M569 P121.0 S0                                            ; physical drive 121.0 goes forwards
M584 X0.0 Y0.1 Z0.2:0.3:0.4:0.5 E121.0                    ; set drive mapping
M671 X35:790:100:780 Y-105:-105:665:665 S10	           	  ; set Z belt positions, max error 5mm
M92 X80.00 Y80.00 Z800.00 E405.00                         ; set steps per mm
M350 X16 Y16 Z16 E16 I1                                 ; configure microstepping with interpolation
M566 X420.00 Y420.00 Z60.00 E960.00                       ; set maximum instantaneous speed changes (Jerk)(mm/min)
M203 X24000.00 Y24000.00 Z1200 E7200                      ; 120 set maximum speeds (mm/min) - 400, 400, 20, 120 (mm/s)
M201 X1500.00 Y1500.00 Z300.00 E5000.00                   ; set accelerations (mm/s^2)
; M204 P1500 T2000                                        ; Set printing acceleration and travel accelerations
M906 X1441 Y1441 Z1441 E1179 I30                          ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                                   ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z0 S1                                          ; set axis minima
M208 X670 Y650 Z645 S0                                    ; set axis maxima

; Endstops
M574 X1 S1 P"!^io3.in"                                    ; configure switch-type (e.g. microswitch) endstop for low end on X via pin !^io3.in
M574 Y2 S1 P"!^io1.in"                                    ; configure switch-type (e.g. microswitch) endstop for high end on Y via pin !^io1.in
M574 Z1 S2                                                ; configure Z-probe endstop for low end on Z

; Z-Probe
; M950 S0 C"121.io0.out"                                    ; create servo pin 0 for BLTouch
; M558 P9 C"121.io0.in" H5 F300:120 T15000 A1 S0.05         ; set Z probe type to bltouch and the dive height + speeds
; G31 P500 X-31.27 Y-36.64 Z2.820                           ; set Z probe trigger value, offset and trigger height
M558 K0 P5 C"!io5.in" H3 F900:120 T15000                    ; set Z probe type to EZABL Pro and the dive height + speeds
G31 K0 P500 X-31.27 Y-46.64 Z1.70                            ; set Z probe trigger value, offset and trigger height
M557 X29:609 Y40:603 P30:30                                 ; define mesh grid

; Scanning Z probe
M558 K1 P11 C"120.i2c.ldc1612" F24000 T24000 B1             ; configure SZP as probe 1, type 11, on CAN address 120
M308 A"SZP coil" S10 Y"thermistor" P"120.temp0"             ; thermistor on SZP coil
G31 K1 X-25 Y0 Z1.40                                         ; define probe 1 offsets and trigger height
M558.2 K1 S13 R147095                                       ; set drive current and reading offset
;M558.1 K1 S1
M557 X29:609 Y40:603 P30:30                                 ; Define mesh grid for probe 1 (overwrites probe 0 mesh grid)

; Filament Sensor
; M591 D0 P3 C"121.io1.in" S1 L24.84 R35:130 E5           ; Duet3D Rotating Magnet Filament Monitor connected to Toolboard 1LC io1
; M591 D0 P1 C"121.io2.in" S1                             ; Dyze Design SENTINEL Filament Detector connected to Toolboard 1LC io2
M591 D0 P7 C"121.io2.in" S1 L1.246 R50:200 E40            ; Dyze Design SENTINEL Filament Detector connected to Toolboard 1LC io2

; Heaters
M308 S0 P"temp0" Y"thermistor" T100000 B4138              ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0                                        ; create bed heater output on out0 and map it to sensor 0
M307 H0 B0 R0.391 C260.7 D2.75 S1.00                      ; enable bang-bang mode for the bed heater and set PWM limit
M140 H0                                                   ; map heated bed to heater 0
M143 H0 S120                                              ; set temperature limit for heater 0 to 120C
M308 S1 P"121.temp0" Y"thermistor" T100000 B4725 C7.06e-8 ; configure sensor 1 as thermistor on pin 121.temp0
M950 H1 C"121.out0" T1                                    ; create nozzle heater output on 121.out0 and map it to sensor 1
M307 H1 R2.135 K0.524:0.000 D2.62 E1.35 S1.00 B0 V24.1    ;M307 H1 B0 R1.891 C265.1 D5.94 S1.00 V24.2; disable bang-bang mode for heater  and set PWM limit
M143 H1 S280                                              ; set temperature limit for heater 1 to 280C

; Fans
M950 F0 C"121.out1" Q500                                  ; create fan 0 on pin 121.out1 and set its frequency
M106 P0 S0 H-1                                            ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"121.out2" Q500                                  ; create fan 1 on pin 121.out2 and set its frequency
M106 P1 S1 H1 T45                                         ; set fan 1 value. Thermostatic control is turned on

; LED Extrude Lights
; M950 E0 C"121.io1.in" T1 U10 Q3000000


; Accelerometer
M955 P121.0 I54 ; specify orientation of accelerometer on Toolboard 1LC with CAN address 121
M955 P120.0 I45 ; Add accelerometer on SZP with CAN address 120 and specify orientation

; Low power automatic pause and save
M911 S22.5 R23.3 P"M913 X0 Y0 M104 S0 M140 S0 M107 G91 M83 G1 Z3 E-5 F1000"; G91 M83 G1 Z1"    

; Tools
M563 P0 D0 H1 F0:1                                        ; define tool 0
G10 P0 X0 Y0 Z0                                           ; set tool 0 axis offsets
G10 P0 R0 S0                                              ; set initial tool 0 active and standby temperatures to 0C

; Firmware Retraction
;M207 S0.6 F2400 Z0.4                                     

; Custom settings are not defined
; M572 D0 S0.018						                          ; pressure advance
M593 P"zvd" F27.7				                              ; input shaping

charliedrums

I updated to a raspberry PI 5 when there was an update to include the Pi 5 not to long ago. So, I decided to do a new install on a Pi 4 with a new 64gb card. For the pi 4 I used the image 2024-04-19-DuetPi-arm64.img. Once I booted with the new pi image, I updated everything through Putty so that I’m on 3.5.2 but this time around on a raspberry pi 4. I started the same 8 hour print to see how it goes.

Here is the diagnostic of the board and the 1lc right after I started the print. So far it has been an hour into the print. I’ll update accordingly.

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91716 of which 3224 recycled
Never used RAM 92212, free system stack 143 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,nWait 7,0.9%,819) HEAT(3,nWait 6,0.0%,321) Move(4,nWait 6,1.2%,211) CanReceiv(6,nWait 1,0.0%,792) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,348) TMC(4,nWait 6,9.6%,53) MAIN(2,running,87.9%,101) IDLE(0,ready,0.3%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 00:18:39 ago, cause: software
Last software reset at 2024-06-26 18:23, reason: User, Platform spinning, available RAM 95692, slot 2
Software reset code 0x6000 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044a000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 37.9, current 41.6, max 41.7
Supply voltage: min 23.8, current 24.0, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/88/88, gc cycles 0
Events: 0 queued, 0 completed
Driver 0: ok, SG min 0, mspos 283, reads 12251, writes 21 timeouts 0
Driver 1: ok, SG min 0, mspos 796, reads 12251, writes 21 timeouts 0
Driver 2: ok, SG min 0, mspos 43, reads 12251, writes 21 timeouts 0
Driver 3: ok, SG min 0, mspos 949, reads 12251, writes 21 timeouts 0
Driver 4: ok, SG min 0, mspos 757, reads 12251, writes 21 timeouts 0
Driver 5: ok, SG min 0, mspos 187, reads 12251, writes 21 timeouts 0
Date/time: 2024-06-26 18:41:48
Slowest loop: 101.55ms; fastest: 0.04ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 232121ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 94 ticks, disabled
Moves shaped first try 687, on retry 298, too short 380, wrong shape 6976, maybepossible 58
=== DDARing 0 ===
Scheduled moves 9303, completed 9280, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 40], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.2
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X320.627014 Y339.914001 E0.037090" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 18737, received 33044, lost 0, errs 1, boc 0
Longest wait 3ms for reply type 6013, peak Tx sync delay 243, free buffers 50 (min 48), ts 5596/5595/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 43540/43540
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 1824/3032-0, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X320.627 Y339.914 E.03709
Buffered code: G1 X312.601 Y339.914 E.46182
Buffered code: G1 E-.6 F2400
Buffered code: G1 F12000
Buffered code: G1 X315.759 Y339.914 E-.6
Buffered code: G1 Z3.8 F720
Buffered code: G1 X322.543 Y347.759 F15000
Buffered code: G1 Z3.2 F720
Buffered code: G1 E1.2 F2400
Buffered code: G1 F3000
Buffered code: G1 X322.543 Y349.856 E.12066
Buffered code: G1 X337.457 Y349.856 E.85816
Buffered code: G1 X337.457 Y347.759 E.12066
Buffered code: G1 X347.399 Y314.669 F15000
Buffered code: G1 F3000
Buffered code: G1 X347.399 Y312.572 E.12066
Buffered code: G1 X312.601 Y312.572 E2.0023
Buffered code: G1 X312.601 Y314.669 E.12066
Buffered code: G1 E-.6 F2400
Buffered code: G1 F12000
Buffered code: G1 X312.601 Y312.572 E-.39843
Buffered code: G1 X313.662 Y312.572 E-.20157
Buffered code: G1 Z3.8 F720
Buffered code: G1 X310.115 Y315.058 F15000
Buffered code: G1 Z3.2 F720
Buffered code: G1 E1.2 F2400
Buffered code: G1 F3000
Buffered code: G1 X349.885 Y315.058 E2.28839
Buffered codes: 1200 bytes total
Code buffer space: 1824
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.48, max time between full transfers: 155.5ms, max pin wait times: 57.1ms/6.5ms
Codes per second: 7.94
Maximum length of RX/TX data transfers: 4420/1140

1LC diagnostic

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3220, free system stack 71 words
Tasks: Move(3,nWait 7,0.1%,90) HEAT(2,nWait 6,0.3%,90) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.1%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,delaying,3.7%,52) MAIN(1,running,91.0%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.8%,112), total 100.0%
Owned mutexes:
Last reset 00:18:41 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 0, write errors 3, ifcnt 11, reads 32054, writes 2584, timeouts 3, DMA errors 0, CC errors 2562, failedOp 0x72, steps req 0 done 468382
Moves scheduled 7701, completed 7700, in progress 1, hiccups 0, segs 26, step errors 0, maxLate 0 maxPrep 335, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/5, peak Rx sync delay 240, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 4.4, current 23.5, max 24.6
MCU temperature: min 40.0C, current 55.6C, max 55.6C
Last sensors broadcast 0x00000002 found 1 26 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 22784, send timeouts 0, received 22157, lost 0, errs 0, boc 0, free buffers 18, min 17, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 362, adv 36231/74671
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 3, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 1 to 32us, poll 2 to 1421us
Driver 0: ok

charliedrums

Well, it happened again at around 3 hour and 12 minutes in it started over extruding again. This time I have not stopped the print. I just disabled the filament sensor and am going to let it print a couple of hours to have a visual on where exactly it goes wrong.

Here are the diagnostics of as of now, after it started over extruding.

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.5.2 (2024-06-11 17:13:58) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 155360
Dynamic ram: 91852 of which 3088 recycled
Never used RAM 92212, free system stack 134 words
Tasks: LASER(5,nWait 7,0.0%,169) SBC(2,nWait 7,1.0%,819) HEAT(3,nWait 6,0.0%,321) Move(4,nWait 6,2.7%,211) CanReceiv(6,nWait 1,0.0%,771) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,346) TMC(4,nWait 6,9.7%,53) MAIN(2,running,86.5%,101) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 03:26:07 ago, cause: software
Last software reset at 2024-06-26 18:23, reason: User, Platform spinning, available RAM 95692, slot 2
Software reset code 0x6000 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044a000 BFAR 0x00000000 SP 0x00000000 Task SBC Freestk 0 n/a
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 40.9, current 43.2, max 43.2
Supply voltage: min 23.8, current 23.9, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/152/152, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 447, reads 34871, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 358, reads 34871, writes 0 timeouts 0
Driver 2: ok, SG min 0, mspos 337, reads 34871, writes 0 timeouts 0
Driver 3: ok, SG min 0, mspos 655, reads 34871, writes 0 timeouts 0
Driver 4: ok, SG min 0, mspos 463, reads 34871, writes 0 timeouts 0
Driver 5: ok, SG min 0, mspos 481, reads 34871, writes 0 timeouts 0
Date/time: 2024-06-26 21:49:16
Slowest loop: 51.41ms; fastest: 0.05ms
=== Storage ===
Free file entries: 20
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 26, maxWait 189738ms, bed compensation in use: mesh, height map offset 0.000, max steps late 0, min interval 0, bad calcs 0, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 106 ticks, disabled
Moves shaped first try 5639, on retry 5272, too short 6461, wrong shape 194305, maybepossible 1481
=== DDARing 0 ===
Scheduled moves 235144, completed 235107, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== DDARing 1 ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X354.319000 Y309.311005 E0.101450" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause* is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x80000007
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== Filament sensors ===
check 0 clear 0
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 317673, received 320618, lost 0, errs 0, boc 0
Longest wait 6ms for reply type 6024, peak Tx sync delay 379, free buffers 50 (min 49), ts 56240/56240/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 25733/25733
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x24cfc
Buffer RX/TX: 3024/512-4080, open files: 0
=== Duet Control Server ===
Duet Control Server version 3.5.2 (2024-06-12 07:12:47, 64-bit)
HTTP+Executed:
> Executing M122
File 0:/gcodes/Guiro 12in_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
>> Doing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
File:
Buffered code: G1 X354.319 Y309.311 E.10145
Buffered code: G1 X355.033 Y311.045 E.13012
Buffered code: G1 X355.661 Y312.813 E.13019
Buffered code: G1 X356.205 Y314.607 E.13008
Buffered code: G1 X356.666 Y316.421 E.12987
Buffered code: G1 X357.045 Y318.247 E.12941
Buffered code: G1 X357.397 Y320.497 E.15803
Buffered code: G1 X357.563 Y321.95 E.10148
Buffered code: G1 X357.699 Y323.815 E.12976
Buffered code: G1 X357.75 Y325.703 E.13106
Buffered code: G1 X357.713 Y327.535 E.12715
Buffered code: G1 X357.541 Y329.761 E.15492
Buffered code: G1 X357.368 Y331.11 E.09437
Buffered code: G1 X357.015 Y333.005 E.13376
Buffered code: G1 X356.656 Y334.436 E.10237
Buffered code: G1 X356.222 Y335.812 E.10012
Buffered code: G1 X355.764 Y337.028 E.09016
Buffered code: G1 X355.384 Y337.898 E.06588
Buffered code: G1 X354.879 Y338.912 E.0786
Buffered code: G1 X353.981 Y340.442 E.1231
Buffered code: G1 X353.31 Y341.42 E.0823
Buffered code: G1 X352.698 Y342.217 E.06973
Buffered code: G1 X352.042 Y342.991 E.0704
Buffered code: G1 X351.344 Y343.741 E.07109
Buffered code: G1 X350.607 Y344.462 E.07154
Buffered code: G1 X349.22 Y345.659 E.12713
Buffered code: G1 X348.202 Y346.428 E.08853
Buffered code: G1 X347.349 Y347.011 E.07169
Buffered code: G1 X345.778 Y347.961 E.12739
Buffered code: G1 X344.865 Y348.446 E.07174
Buffered code: G1 X343.71 Y348.995 E.08874
Buffered code: G1 X342.01 Y349.696 E.1276
Buffered codes: 1536 bytes total
Code buffer space: 2512
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 39.20, max time between full transfers: 56.5ms, max pin wait times: 51.8ms/21.5ms
Codes per second: 20.63
Maximum length of RX/TX data transfers: 4440/1140

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.2 (2024-06-10 13:24:04)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 3196, free system stack 71 words
Tasks: Move(3,nWait 7,0.3%,84) HEAT(2,nWait 6,0.4%,90) CanAsync(5,nWait 4,0.0%,52) CanRecv(3,nWait 1,0.2%,70) CanClock(5,nWait 1,0.0%,58) ACCEL(3,nWait 6,0.0%,52) TMC(2,delaying,3.7%,52) MAIN(1,running,90.7%,314) IDLE(0,ready,0.0%,26) AIN(2,delaying,4.9%,112), total 100.0%
Owned mutexes:
Last reset 03:26:10 ago, cause: software
Last software reset data not available
Driver 0: pos 0, 405.0 steps/mm, ok, SG min 0, read errors 1, write errors 1, ifcnt 35, reads 48266, writes 40994, timeouts 4, DMA errors 0, CC errors 40994, failedOp 0x72, steps req 0 done 9378961
Moves scheduled 224153, completed 224150, in progress 1, hiccups 0, segs 27, step errors 0, maxLate 0 maxPrep 367, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0, ebfmin 0.00 max 1.00
Peak sync jitter 0/8, peak Rx sync delay 260, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 19.7, current 23.3, max 24.4
MCU temperature: min 40.0C, current 54.6C, max 56.1C
Last sensors broadcast 0x00000002 found 1 29 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 230643, send timeouts 0, received 362699, lost 0, errs 0, boc 0, free buffers 18, min 17, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 390, adv 36112/109819
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, contentions 0, other errors 0
=== Filament sensors ===
Interrupt 1 to 105us, poll 2 to 1701us
Driver 0: ok

I don't really understand it. The last thing that comes to mind is changing the 1LC board? I'm at a loss here. At this point it feels like I'm punching in the dark. If anybody has any info or what to try next I appreciate it.

*edit: The print separated from the build plate so I'm including some pictures of the how the print looks after the over extrusion. Also uploaded two videos. one at the start of the print and the other when it starts over extruding. Notice the sound of the retractions. It sounds off.

photo_2024-06-26_21-58-31 (2).jpg
photo_2024-06-26_21-58-31 (3).jpg

video_2024-06-26_22-01-48.mp4 video_2024-06-26_22-01-39.mp4

gloomyandy

@charliedrums If you think this may be a problem with 3.5.2 then perhaps try going back to whatever version of RRF you had installed before and see if the problem goes away?

charliedrums

@gloomyandy
Right now, I went back to DuetPi 2023-09-06 (buster) on a pi 4, from there I updated to RepRapFirmware 3.5.0 RC4. I would stay in 3.4.6 but I have the Zscaning probe and If I recall correctly that one is not usable in 3.4.6.

For some reason Duet web control doesn’t update to 3.5.0RC4 and stays on 3.4.6 or I might be updating it wrong. Either way I’m on another test print 2h 13m 51s in so far.

gloomyandy

@charliedrums What version of RRF where you using before you started having these problems? Ideally you want to go back to that (especially if you still have a problem with RC4). You probably do not need the scanning probe to be working to run a test print, you can use a previously saved mesh.

charliedrums

@gloomyandy
I was using 3.5.0 and I ran 8 to 20 hour prints without any problem. The print I was running just had the same issue at the 2 hour 40 mark it started over extruding. It has been printing fine for a about two months. Could it be a busted 1LC board. My 1LC is the 1.2 not the 1.2a. I can get the 1.3 from fillastruder and try it out to see.

droftarts

@charliedrums Sorry you're having problems. @dc42 needs to look at your M122 reports to see if there's anything in there. I can see a few things that may help troubleshooting:

The 1LC has not reset, according to the M122 B121 report. Nor has the steps per mm on the extruder driver changed, it's still 405. The board doesn't seem to have overheated, and there's no CAN or I2C errors, either. You could update the bootloader on the 1LC, current version is 2.8, you're on 2.3. See https://docs.duet3d.com/en/User_manual/RepRapFirmware/Updating_bootloader

I can't see any other errors in the M122 report for the 6HC, either. I think as far as RRF is concerned, nothing happened.

When it starts printing with double the extrusion, does the motor sound the same? I'm wondering if something is causing the microstepping mode to change to x8 rather than x16 (you say there's a 'weird extruder retraction sound'). It could be a heat related effect on the 1LC, but without running a test print on a previous RRF version that was working for you, it's hard to say why this would happen at the same time as updating to RRF 3.5.2. If it happens again, can you send M350 and check the microstepping in use is still x16, as per your config.g?

I can see from your video that some of the wiring is exposed where it is crimped into the connector:

Check for potential shorts of those. Can you post a sharp, hi resolution image of the 1LC?

Is the hot end metal work grounded in some way? We advise this to minimise the chances of static shocks. See https://docs.duet3d.com/Duet3D_hardware/Duet_3_family/Duet_3_Toolboard_1LC#wiring-notes

We recommend connecting the hot end metalwork to ground on the toolboard via a resistor (10k to 1M Ohm), if it is not grounded through its mounting system. This will prevent the hot end building up static charge, which might otherwise occur as filament is extruded and may then flash over to the tool board thermistor input, causing damage.

Again, these don't really explain why it started happening when you updated to 3.5.2, though.

Ian

gloomyandy

@charliedrums Just to be clear, did the test with RC.4 also start to over extrude? If that was the case then it seems unlikely that it is anything in 3.5.2 that is causing the problems, especially if you were able to print ok with 3.5.0. Why did you choose to go back to 3.5-rc4 rather than 3.5.0? You might want to try 3.5.0 just to be sure, that the problem is not related to the firmware.

charliedrums

@droftarts said in Random overextrusion after 3+hours of printing FW 3.5.2:

ut without running a test print on a previous RRF version that was working for you, it's hard to say why this would happen at the same time as updating to RRF 3.5.2. If it happens again, can you send M350 and check the microstepping in use is still x16, as per your

Ok, so I went back to 3.4.6 and ran the file again and the same thing happened at around 2-3 hours in, so that takes out the possibility of being software related. I think?
Here is the diagnostics:

=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.4.6 (2023-07-21 14:11:38) running on Duet 3 MB6HC v1.01 (SBC mode)
Board ID: 08DJM-956BA-NA3TN-6JTD0-3SJ6S-1V82V
Used output buffers: 1 of 40 (40 max)
=== RTOS ===
Static ram: 153252
Dynamic ram: 67620 of which 0 recycled
Never used RAM 126272, free system stack 128 words
Tasks: SBC(resourceWait:,0.8%,446) HEAT(notifyWait,0.0%,321) Move(notifyWait,2.5%,214) CanReceiv(notifyWait,0.0%,773) CanSender(notifyWait,0.0%,327) CanClock(delaying,0.0%,347) TMC(notifyWait,8.1%,56) MAIN(running,88.5%,923) IDLE(ready,0.0%,30), total 100.0%
Owned mutexes: HTTP(MAIN)
=== Platform ===
Last reset 04:20:10 ago, cause: power up
Last software reset details not available
Error status: 0x04
Aux0 errors 0,0,0
Step timer max interval 131
MCU temperature: min 41.5, current 42.5, max 42.5
Supply voltage: min 23.8, current 24.0, max 24.0, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 12.0, current 12.1, max 12.1, under voltage events: 0
Heap OK, handles allocated/used 99/0, heap memory allocated/used/recyclable 2048/64/64, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, mspos 917, reads 44703, writes 0 timeouts 0
Driver 1: ok, SG min 0, mspos 860, reads 44703, writes 0 timeouts 0
Driver 2: standstill, SG min 0, mspos 792, reads 44703, writes 0 timeouts 0
Driver 3: standstill, SG min 0, mspos 168, reads 44703, writes 0 timeouts 0
Driver 4: standstill, SG min 0, mspos 488, reads 44703, writes 0 timeouts 0
Driver 5: standstill, SG min 0, mspos 408, reads 44703, writes 0 timeouts 0
Date/time: 2024-06-27 16:15:47
Slowest loop: 29.62ms; fastest: 0.04ms
=== Storage ===
Free file entries: 10
SD card 0 not detected, interface speed: 37.5MBytes/sec
SD card longest read time 0.0ms, write time 0.0ms, max retries 0
=== Move ===
DMs created 125, segments created 28, maxWait 204ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 224744, completed 224704, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state 3
=== AuxDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Segments left: 1
Movement lock held by null
HTTP* is doing "M122" in state(s) 0 0, running macro
Telnet is idle in state(s) 0
File* is doing "G1 X340.993011 Y297.888000 E0.105450" in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger* is idle in state(s) 0
Queue* is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause* is idle in state(s) 0
Code queue is empty
=== Filament sensors ===
Extruder 0 sensor: no data received
=== CAN ===
Messages queued 10186, received 8489, lost 0, boc 0
Longest wait 5ms for reply type 6024, peak Tx sync delay 372, free buffers 50 (min 49), ts 1726/1726/0
Tx timeouts 0,0,0,0,0,0
=== SBC interface ===
Transfer state: 5, failed transfers: 0, checksum errors: 0
RX/TX seq numbers: 19094/19094
SPI underruns 0, overruns 0
State: 5, disconnects: 0, timeouts: 0 total, 0 by SBC, IAP RAM available 0x2ab5c
Buffer RX/TX: 1392/2864-0, open files: 0
=== Duet Control Server ===
Duet Control Server v3.4.6
File /opt/dsf/sd/gcodes/Guiro 12in_3.4.6Test_0.6n_0.3mm_PLA_EXOCUBE_8h39m.gcode is selected, processing
HTTP:
Executing macro 0:/macros/Diagnostics, started by M98 P"0:/macros/Diagnostics"
> Next stack level
File:
Buffered code: G1 X340.993 Y297.888 E.10545
Buffered code: G1 X342.308 Y298.665 E.10599
Buffered code: G1 X343.57 Y299.538 E.10648
Buffered code: G1 X344.154 Y300.008 E.05202
Buffered code: G1 X344.773 Y300.507 E.05517
Buffered code: G1 X345.912 Y301.567 E.10797
Buffered code: G1 X346.982 Y302.707 E.10849
Buffered code: G1 X347.988 Y303.921 E.1094
Buffered code: G1 X348.928 Y305.199 E.11008
Buffered code: G1 X349.801 Y306.533 E.11063
Buffered code: G1 X350.614 Y307.927 E.11198
Buffered code: G1 X351.353 Y309.347 E.11108
Buffered code: G1 X352.021 Y310.789 E.11027
Buffered code: G1 X352.628 Y312.265 E.11074
Buffered code: G1 X353.165 Y313.751 E.10964
Buffered code: G1 X353.636 Y315.246 E.10876
Buffered code: G1 X354.039 Y316.739 E.10731
Buffered code: G1 X354.375 Y318.223 E.10558
Buffered code: G1 X354.641 Y319.687 E.10325
Buffered code: G1 X354.846 Y321.122 E.10058
Buffered code: G1 X354.995 Y322.53 E.09825
Buffered code: G1 X355.09 Y323.879 E.09384
Buffered code: G1 X355.137 Y325.313 E.09956
Buffered code: G1 X355.137 Y326.466 E.08001
Buffered code: G1 X355.088 Y327.775 E.09089
Buffered code: G1 X355.005 Y328.922 E.0798
Buffered code: G1 X354.754 Y330.938 E.14097
Buffered code: G1 X354.577 Y331.92 E.06924
Buffered code: G1 X354.355 Y332.922 E.07121
Buffered code: G1 X354.128 Y333.784 E.06185
Buffered code: G1 X353.652 Y335.265 E.10794
Buffered code: G1 X353.182 Y336.446 E.0882
==> 1536 bytes
Code buffer space: 1272
Configured SPI speed: 8000000Hz, TfrRdy pin glitches: 0
Full transfers per second: 38.87, max time between full transfers: 43.7ms, max pin wait times: 56.7ms/1.0ms
Codes per second: 21.21
Maximum length of RX/TX data transfers: 3672/1664

1LC

Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.4.6 (2023-07-21 14:17:33)
Bootloader ID: SAMC21 bootloader version 2.3 (2021-01-26b1)
All averaging filters OK
Never used RAM 2484, free system stack 25 words
Tasks: Move(notifyWait,0.6%,99) HEAT(notifyWait,0.5%,75) CanAsync(notifyWait,0.0%,65) CanRecv(notifyWait,0.1%,74) CanClock(notifyWait,0.0%,65) ACCEL(notifyWait,0.0%,61) TMC(delaying,2.9%,57) MAIN(running,90.9%,351) IDLE(ready,0.0%,26) AIN(delaying,5.0%,142), total 100.0%
Last reset 04:20:12 ago, cause: power up
Last software reset data not available
Driver 0: pos 7425929, 405.0 steps/mm,ok, SG min 0, read errors 0, write errors 1, ifcnt 238, reads 13513, writes 18073, timeouts 1, DMA errors 0, CC errors 18073, failedOp 0xec, steps req 281499 done 281503
Moves scheduled 215982, completed 215979, in progress 1, hiccups 0, step errors 0, maxPrep 584, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter 1/5, peak Rx sync delay 210, resyncs 0/0, next step interrupt due in 134 ticks, enabled
VIN voltage: min 20.9, current 23.7, max 24.3
MCU temperature: min 44.2C, current 53.7C, max 57.6C
Last sensors broadcast 0x00000002 found 1 152 ticks ago, 0 ordering errs, loop time 1
CAN messages queued 7108, send timeouts 0, received 10187, lost 0, free buffers 37, min 36, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 424, adv 36414/74668
Accelerometer: LIS3DH, status: 00
I2C bus errors 0, naks 0, other errors 0
=== Filament sensors ===
Interrupt 5 to 24us, poll 24 to 1733us
Driver 0: ok

I also ran M350 while printing with the over extrusion and it still says everything is a x16.

	M350
Microstepping - X:16(on), Y:16(on), Z:16(on), E:16(on)

As for the wire I tested all connections with multimeter and there doesn’t seem to be any shorts I could find. I however did not ground the hot end metal work, never did since I put it together around 2022 and it is mounted directly on the Hermes/Hemera which is mounted on a 0.25in SS bracket. While in the over extrusion face of the print I touched everything in the 1LC and nothing feels hot to the touch.

Completely missed that in the documentation. I’ve tried 3.4.6, 3.5.0RC4,3.5.1 and 3.5.2 and the same thing keeps happening. And up to this point everything was working fine even when jumping to unstable releases. I'm leaning towards a faulty 1LC unless there is something that I'm missing.

Here are the pictures requested:
photo_2024-06-27_16-08-35 (4).jpg

*Edit:
Also, I live in Tampa Florida and these past couple of weeks we’ve seen some thunder storms for about two weeks straight. Don’t know if it is relevant but might as well mention it. I do not have the printer on an UPS.

charliedrums

@gloomyandy
Yes, so far I’ve tried 3.4.6, 3.5.0RC4,3.5.1 and 3.5.2 and the same thing keeps happening. I'm leaning towards a faulty 1LC unless there is something that I'm missing .

droftarts

@charliedrums said in Random overextrusion after 3+hours of printing FW 3.5.2:

I however did not ground the hot end metal work, never did since I put it together around 2022 and it is mounted directly on the Hermes/Hemera which is mounted on a 0.25in SS bracket.

Is the SS bracket grounded? If not, I don't think it would hurt to try, or make sure the motor is grounded, particularly if the alternative is replacing the 1LC. May be the hot, humid, thundery weather, and a particular filament is enough to make it more susceptible to static discharge. I'd imagine it's discharging through the motor wires, into the driver, and messing that up. To reiterate our advice:

We recommend connecting the hot end metalwork to ground on the toolboard via a resistor (10k to 1M Ohm), if it is not grounded through its mounting system. This will prevent the hot end building up static charge, which might otherwise occur as filament is extruded and may then flash over to the tool board thermistor input, causing damage.

https://docs.duet3d.com/Duet3D_hardware/Duet_3_family/Duet_3_Toolboard_1LC#wiring-notes

Ian

gloomyandy

@charliedrums Is there any chance this could be related to temperature of your extruder or extruder motor? I wonder if after a long time your are getting "heat creep" that impacts the ability for the extruder to perform a retract, perhaps the filament is softened and so the extruder fails to grip it? You mentioned earlier that you needed to reboot for the problem to go away. Couple of tests you could try....

Wait for the problem to happen, reboot the computer and start the print again (do not allow any time for things to cool down).
Wait for the problem to happen, do not reboot, but allow the printer to cool down completely, then start the print again.

If in case 1 the problem does not happen for a few hours we can probably ignore heat. If in case 2 it takes a couple of hours for the problem to appear, then maybe heat is involved.

When you fitted the SZP, did you make any other changes? Is there any chance that the way the SZP is fitted that the airflow around the extruder has been reduced/changed?

charliedrums

@droftarts
It was not grounded but it is now. Since it takes a couple of days to get here I went and ordered a 1LC v1.3 board to see if that changes anything.

I updated the bootloader on the 1LC and I have grounded the bracket and now the screws and the hemera are grounded. This time I started a print and it started over extruding right from the start. Maybe now with the updated bootloader and grounded everything, updaye everything to 3.5.2 and see what happens? I'll keep trying stuff until the new 1LC gets here. I'll keep the thread updated to my findings.

charliedrums

@gloomyandy
I don't think it is heat related. I do a lot of hueforge, so the way I have the pause script is to turn off the extruder and park the extruder. So at least twice of the tests have been, set the print and go to bed, when I wake up it has been paused for a couple of hours letting the extruder cool down. I proceed to bring it up to temperature remove filament, trim it, and finally purge filament before resuming the print. After this the problem persists. But I'll give ot a try.

I bought a new 1lcv1.3 from filastruder so I have a couple of days before it gets here where I can keep investigating to see if I can pinpoint the problem.

charliedrums

Small update. While waiting for the new 1LCv1.3 to get here I decided to remake all the cable harnesses that connect to the 1LC board I got the correct crimper and crimped everything correctly with new JST-PH connectors (trying to get these perfect is not that easy). After this I tried again but same thing After a couple of hours the extruder randomly starts over extruding. So this eliminates any bad crimps or harness connections.

I also took the board off the extruder and inspected everything to see if there was any visible damage. But there was nothing that I could see. Is there any test to see if the board is busted in any way?

OwenD

@charliedrums
Have you scanned the Gcode at that area?
I once had a similar issue that was doing my head in.
It turned out that in one of the settings in PrusaSlicer, I had a value entered as a percentage when it should have been an 1 based factor.
So instead of be 75% of the extrusion value, it was 75X the value.
I never figured out if I made an error, or there was a change in the software (unlikely), or if it was me caopying configs between prusa slicer and super slicer.
I think it was in overhangs.
In any case, maybe check for sudden increases in the E values for moves in that area.

deckingman

I haven't read this entire thread so I might have missed something but another option/thing to check is if the Z axis is moving properly. If the Z axis has some "stiction" or other movement related issue which prevents it from moving the full layer height, then this can seem like over extrusion. i.e. if you extrude enough filament for (say) 0.3mm layer height but the Z axis has only moved (say) 0.1mm, then this can seem like over extrusion.

charliedrums

@OwenD I have printed the gcode before. Probably like 30 t50 times and it has always worked. Still gave it a look but found nothing out of the ordinary.

Solved Random overextrusion after 3+hours of printing FW 3.5.2